Visors for automotive vehicles and methods of forming the same

ABSTRACT

A family of visors for automotive vehicles is disclosed. Each member of the family includes at least some degree of commonality and preferably some degree of difference with one or more members of the family.

TECHNICAL FIELD

[0001] The present invention relates to visors for automotive vehicles.More particularly, the present invention relates to families of visorsfor one or more different automotive vehicles.

BACKGROUND OF THE INVENTION

[0002] It is known to employ visors in automotive vehicles for blockingundesirable direct or reflected light to shield the vision of drivers orpassengers in the vehicles. It is generally desirable to provide avariety of different visors to satisfy variable conditions presentwithin different automotive vehicles and to satisfy variable desires ofautomotive vehicle consumers. For example, automotive vehicles caninclude variable conditions such as size, shape, style, cost efficiencyand the like. Thus, a variety of different visors may be desirable tocomplement such conditions. Additionally, automotive consumers may wanta variety of visors with various visor features and styles. However,manufacturing of a variety of visors can be costly due to the variety oftools, materials, manufacturing techniques and the like that may need tobe employed to form the visors. Thus, it would be desirable to providevisors with some degree of commonality to minimize manufacturing costswhile still providing a variety of features for the visors.

SUMMARY OF THE INVENTION

[0003] According to one aspect, the present invention provides a familyof visors including at least a first visor and a second visor. The firstvisor and the second visor both include a first side and a second side.The first sides are substantially identical to each other and preferablyeach of the first sides includes a generally rectangular perimeterportion, which may be formed of a polymer such as polypropylene. Each ofthe first sides also preferably includes a generally flat centralportion, which may be an insert or otherwise. The first and secondvisors also preferably both include a second side. Each of the secondsides of the visors also preferably includes a generally rectangularperimeter portion, which may be formed of a polymer such aspolypropylene. The second side of the first visor preferablyaccommodates a first peripheral that is different from a secondperipheral that is accommodated by the second side of the second visor.In a highly preferred embodiment, the first side of the first and secondvisors at least partially attaches to the second side of the first andsecond visors by snap fitting.

[0004] According to another aspect, the present invention provides amethod of forming a visor family for automotive vehicles. According tothe method, a first side of a first visor and a first side of a secondvisor are provided wherein the first sides of the visors aresubstantially identical to each other and at least a portion of thefirst sides of the visors is formed of a polymer. Preferably, the firstsides of the visors each include a first perimeter portion that isformed of a polymer (e.g., an injection molded polymer) and a firstinsert that is attached to and substantially surrounded by the firstperimeter portion. Each of the first and second visors is also providedwith a second side wherein the second side of the first visor isconfigured to accommodate a first peripheral and the second side of thesecond visor is configured to accommodate a second peripheral differentfrom the first peripheral. Preferably, the second sides of the first andsecond visor are respectively attached to the first sides of the firstand second visor.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] These and other objects, features, aspects, and advantages of theinvention will become apparent upon consideration of the specificationand appended drawings in which:

[0006]FIG. 1(a) illustrates a perspective view of a base visor in afamily of visors;

[0007]FIG. 1(b) is a sectional view of the base visor of FIG. 1(a) takenalong line 1(b)-1(b); FIGS. 2(a)-2(b) illustrate perspective views of anadvanced visor in the family of visors;

[0008]FIG. 2(c) is a sectional view of the advanced visor of FIGS.2(a)-2(b) taken along line 2(c)-2(c);

[0009] FIGS. 3(a)-3(b) respectively illustrate perspective views of anadvanced visor in the family of visors;

[0010]FIG. 3(c) is a sectional view of the advanced visor of FIGS.3(a)-3(b) taken along line 3(c)-3(c);

[0011]FIG. 4 illustrates a perspective view of a visor in the family ofvisors;

[0012] FIGS. 5(a)-5(c) illustrate three perspective views of an advancedvisor in the family of visors;

[0013]FIG. 5(d) is a sectional view of the advanced visor of FIGS.5(a)-5(c) taken along line 5(d)-5(d);

[0014] FIGS. 6(a)-6(c) illustrate three perspective views of an advancedvisor in the family of visors;

[0015]FIG. 6(d) is a sectional view of the base visor of FIG. 6(a)-6(c)taken along line 6(d)-6(d);

[0016] FIGS. 7(a)-7(b) illustrate perspective views of visors.

DESCRIPTION OF PREFERRED EMBODIMENT

[0017] Generally, the present invention relates to the manufacture of afamily of visors having at least some degree of commonality between thevisors within the family to allow for efficient and economicalmanufacturing of the visors. Additionally, the family of visors mayinclude differences between the visors within the family to satisfyconditions presented by various different vehicles and to satisfyconsumer demand for certain types of visors, visor peripherals or both.

[0018] Referring now to FIGS. 1(a)-6(d), there is illustrated a familyof visors 10, 12, 14, 16, 18, 20 for use in one or more automotivevehicles (not shown). Each visor 10-20 includes a fastening assembly 28for attachment to a roof or ceiling portion (not shown) of theautomotive vehicle. Each fastening assembly 28 is attached to a supportmember 32 that is adapted to support a body portion 36 of each visor10-20. Preferably, the support member 32 includes a first elongatedportion 40 extending away from the fastening assembly 28 and an arcuateportion 42 that connects a second elongated portion 44 of the member 32to the first elongated portion 40 such that the second elongated portion44 extends generally perpendicular to the first elongated portion 40.The support member 32 may be rotatably attached to the fasteningassembly 28 for allowing the support member 32 and, thus, the bodyportion 36 of each visor 10-20 to rotate relative to the fasteningassembly 28. The person of skill in the art will recognize thatfastening assemblies and support members having a variety ofconfigurations may be utilized in the present invention.

[0019] Each visor 10-20 of the family includes a first side wall portion50 that can be attached to a second side wall portion 52. In oneembodiment, the first side portion 50 opposes and is generally parallelto the second side portion 52. Preferably, the first portion 50 can beattached (e.g., snap fit, adhesively secured or the like) to the secondside portion 52 to form the body 36 of each visor 10-20. In a mostpreferred embodiment, the first side portion 50 is the portion of eachvisor 10-20 that faces toward the interior of the vehicle when the visor10-20 is in the stowed position, and the second side portion 52 facestoward the roof of the vehicle when in the stowed position.

[0020] Referring specifically to FIGS. 1(a)-1(b), the visor 10illustrated is an embodiment of a base model of the family of visors10-20 referred to herein as the base visor 10. The first side portion 50of the base visor 10 is generally rectangular and includes a generallyrectangular outer perimeter 56 substantially surrounding a generallyflat central wall portion 58. The outer perimeter 56 is generallyarcuate in cross-section as it surrounds the central portion 58. Thefirst side portion 44 can form at least part of an elongated top edgeportion 64 that is generally triangular in cross-section with a hole 66extending along a length of the edge portion 64 for receiving the secondelongated portion 44 of the support member 32.

[0021] The second side portion 52 of the base visor 10 includes agenerally flat portion 70 and a generally rectangular outer perimeterportion 72 that may also be substantially arcuate in cross-section. Thesecond portion 52 may form part of the elongated top edge portion 64 orthe second portion 52 may fit flush to the elongated top edge portion64. The second side portion 52 is preferably designed to fit flush tothe first side portion 50 such that the two portions 56, 52 may besecured together to form the body 36 of the visor 10 with a generallycontinuous outer surface and an at least partially hollow interior 76.

[0022] The first side portion 50 may be secured to the second sideportion 52 according to a variety of methods such as adhesive fasteningand the like. In the preferred embodiment, the first side portion 50 andsecond side portion 52 are snap fit together with male and femaleportions of fasteners 80 (e.g., snaps) that may be distributed as neededor desired upon the first and second side portions 50, 52. Preferably,the snaps 80 or other fastening mechanisms or mediums are dispersedabout the perimeters 72, 56 of the side portions 50, 52. It shall berecognized, however, that fastening mechanisms may be provide in avariety of places upon the first and second side portions 50, 52depending on the configurations of the portions 50, 52

[0023] The first side portion 50 and the second side portion 52 of thebase visor 10 can be made from a variety of materials. In oneembodiment, the first and second side portions 50, 52 are formed of apolymeric material that is preferably molded. In a preferred embodiment,the first and second side portions 50, 52 are formed of polypropyleneand are injection molded in an appropriate mold. In a highly preferredembodiment, at least one or both of the first and second side portions50, 52 and, preferably, the outer perimeter portions 56, 72 includegripping regions 78. The gripping regions 78, as shown, are generallyelliptical but may be formed in nearly any shape or configuration asdesired. Preferably, the gripping regions 78 are formed of different andsofter material or polymer than the rest of the side portions 50, 52.One exemplary material for the gripping regions 78 is a thermoplasticvulcanite such as SANTOPRENE, commercially available from AdvancedElastomer Systems, 388 S. Main Street, Akron, Ohio, 44311-1059. howevera variety of the materials may also be utilized. It is preferable forthe gripping regions 78 to be located where an individual will likelygrab, grasp or grip the visor.

[0024] It shall be recognized that the first side portion 50 and thatsecond side portion 52 may be formed according to a variety ofconfigurations to ultimately form the body 36 of the visor 10.

[0025] Referring to FIGS. 1(a)-6(d), the family of visors 10-20 alsoincludes higher level visors 12-20 that are formed based upon the basevisor 10, but which include features not included in the base visor 10.Such visors 12-20 are referred to herein as advanced visors 12-20.

[0026] Referring to FIGS. 1 (a)-6(d), the first side portion 50 of eachof the advanced visors 12-20, preferably, includes at least some levelof commonality with the first side portion 50 of the base visor 10. In apreferred embodiment, each first side portion 50 of each visor 10-20 ofthe family can be formed using one mold that can receive and shapepolymeric materials. In one embodiment, each of the first side portions50 of the family of visors 10-20 may be substantially identical. Inanother embodiment and as can be seen with reference to FIGS. 2(c),3(c), 5(d) and 6(d), the first side portion 50 of one or more of thevisors 12-20 can also be adapted to include a centralized generallyrectangular insert 84 that substantially provides the flat portion 58 ofthe first side portion 50. The insert 84 may be substantially surroundedby a perimeter portion 88 substantially identical to the perimeterportion 56 of the first side portion 50 of the base visor 10.Preferably, the insert 84 includes a solid base (not shown) that issubstantially surrounded by a cloth material.

[0027] As used herein, inserts 84 that are substantially identical toeach other are typically identical in shape, size and configuration suchthat the inserts may be attached in like manners to substantiallyidentical perimeter portions. It is contemplated, however, that variousinserts 84 may be substantially identical while still includingdifferent aesthetic features (e.g., aesthetic designs, colors, clothdesigns or types etc.).

[0028] In one embodiment, the first side portions 50 of the advancedvisors 12-20 may be formed by placing the insert 84 into the same moldas that used for the first side portion 50 of the base visor 10 followedby injection molding of polypropylene or other like material about theinsert 84 to integrate the insert 84 within the perimeter portions 88 ofthe advanced visors 12-20. In another embodiment, the perimeter portions56, 88 of the first side portions 50 may be formed and the centralportion 58 and the insert 84 may both be treated as inserts to fitwithin the perimeter portions 56, 88. The inserts 58, 84 could be heldwithin the perimeter portions by brackets, adhesives, heat stakinginterference fits or other fastening mechanisms. In another embodiment,each of the visors 10-20 of the family may include the insert 84 or eachfirst side portion 50 of each visor 10-20 may be made of entirelymoldable material (e.g., plastic).

[0029] Advantageously, the base visor 10 and advanced visors 12-20 canbe formed to have substantially identical perimeter portions 56, 88first side portions 50 or other portions with substantially identicalsnaps 80 or other fastening mechanisms thereby allowing each of thefirst side portions 50 to be interchangeably fastened to each of thesecond side portions 52 as will be further discussed below. Alsoadvantageous, the family of visors 10-20 may provide two types of firstside portions 50 (i.e., those with inserts and those without) that canbe formed using substantially the same manufacturing tools and which,can be interchanged with a variety of second side portions 52 of thefamily of visors 10-20.

[0030] The second side portions 52 of the visors 10-20 may be varied toprovide for and accommodate various features and peripherals that may bedesirable for the visors 10-20. The second side portions 52 may alsoinclude a substantially common portion (e.g., its perimeter portion 72)that can be fastened to each of the first side portions 50 while thesecond portion 52 may also be adapted to accommodate or support variousvisor peripherals such as vanities and the like. Preferably, each of thesecond side portions 52 of the visors 10-20 are formed to fasten orotherwise attach to each of the first side portions 50 of the visors10-20.

[0031] Either of the outer perimeter portions 56, 88 of either firstside portion 50, 52 may form all or a portion of the outer periphery ofthe body 36 of each of the visors 10-20 and the outer perimeter portions72 of the other side portion 50, 52 may be adapted to form the remainderof the outer periphery of the body.

[0032] The advanced visor 12 illustrated in FIGS. 2(a)-2(c) includes avanity assembly 100 fitted upon the second side portion 52 of the visor12. The second side portion 52 of the visor 12 is preferably moldedplastic (e.g., polypropylene) and includes fasteners 80 to fit to thefirst side portion 50 in a manner substantially identical to the basevisor 10. The second side portion 52 has been formed (e.g., injectionmolded) to define a generally rectangular cavity 104 for receiving agenerally rectangular vanity cover 106 and a generally rectangularmirror 108. The mirror 108 is mounted in the cavity 104 with one or morebrackets 114 that extend outward from the second side portion 52 tooverlie the outer perimeter of the mirror 108.

[0033] The vanity cover 106 is hingedly attached with fasteners 120 tothe second side portion 52 within the cavity 104. The cover 106 canrotate about the fasteners 120 to selectively open or expose the mirror108.

[0034] The advanced visor 14 of FIGS. 3(a)-3(c) is formed to besubstantially similar or identical to the advanced visor 12 of FIGS.2(a)-2(c), and includes a substantially identical vanity assembly 100.The visor 14 is additionally fitted with a visor extension 126 forextending the light blocking coverage ability of the visor 14. The visorextension 126 preferably, includes a generally rectangular wall 128having a width 130 that extends substantially across an entire width 132of the visor 14. As shown, a portion of the outer perimeter 72 of thefirst and/or second side portions 50, 52 of the visor 14 forms a handle140 of the visor extension 126 such that an individual could grab thehandle 140 and slide the wall 128 of the visor extension 126 into andout of the interior hollow portion 76 which accommodates the visor 14.Preferably, the extension 126 includes one or more gripping regions 78.

[0035] According to one embodiment of the invention, one or more moldsfor forming at least part of the first and/or second side portions 50,52 of the visor 14 may be fitted with inserts for forming the handle 140of the visor extension 126. Notably, the molds receiving the inserts maybe the same as those used to form at least portions of each of thevisors 10-20 of the family. The wall 128 of the extension 126 may beformed integrally with the handle 140 or may be otherwise fastened tothe handle 140.

[0036] The advanced visor 16 of FIG. 4 is designed to allow the body 36of the visor 16 to translate along the second portion 44 of the supportmember 32 for allowing the light blocking coverage ability of the visor16 to be varied by a driver or passenger of an automotive vehicle.Preferably, the second portion 44 of the support member 42 isfrictionally slide fit within the hole 66 of the visor 16 allowingtranslation of the body 36 of the visor 16 while still reliably securingthe body 36 to the second portion 44.

[0037] The advanced visor 18 of FIGS. 5(a)-5(d) includes a first sideportion 50 substantially identical to the first side portions 50 of thevisors 12, 14, 16 of FIGS. 2(a)-4. The second side portion 52 of thevisor 18 includes a cavity 150 that is generally rectangular and spansnearly the entire second side portion 52 with the exception of the outerperimeter 72.

[0038] Preferably, the second side portion 52 of the visor 18 is securedto the first side portion 50 of the visor 18 in a manner similar oridentical to that used to secure together the other visors 10, 12, 14,16. The cavity 150 is configured for receiving and accommodating asecondary visor wall 152. The secondary visor wall 152 spanssubstantially the entire cavity 150 and is rotatable relative to thebody 36 of the visor 18 for providing additional light blockingprotection.

[0039] The secondary visor wall 152 is attached to an arcuate member 156that is rotatably attached to the second side portion 44 of the supportmember 32 to allow the secondary visor wall 152 to rotate relative tothe body portion 36 of the visor 18. Preferably, the secondary visorwall 152 may be used to primarily block light entering an automotivevehicle through a door window (not shown) while the visor body 36 may beused to primarily block light entering an automotive vehicle through awindshield (not shown) of the vehicle. In a most preferred embodiment,the secondary visor wall 152 includes a hollow interior 160, in which,an extension 164 of the secondary visor wall 152 may be disposed. Asshown best in FIG. 5(c), the extension 164 may be selectively exposedrelative to the remainder of the secondary visor wall 152 to extend thecoverage ability of the secondary visor wall 152.

[0040] The advanced visor 20 of FIGS. 6(a)-6(d) is substantiallyidentical to the advanced visor 18 of FIGS. 5(a)-5(d) with the exceptionthat its cavity 170 is at least partially defined by a back wall 172,which supports a vanity assembly 176 substantially identical to thevanity assemblies 100 of FIGS. 2(a)-4. Also, the secondary visor wall152 may not fit as deeply into its cavity 170.

[0041] Visors 180, 182 are also illustrated in FIGS. 7(a)-7(b) to showthat pockets 184 for containing or supporting various items may also beintegrated into the family of visors 10-20. The pockets 184 illustratedare formed of mesh netting and may be sewn or otherwise attached to thevisors 180, 182.

[0042] As shown herein, one family of visors 10-20 has been illustratedand discussed. However, is contemplated that two or more families may bedeveloped based upon the family shown to provide light blocking coveragefor the various automotive vehicle lines provided by automotivemanufacturers. As an example, a family of relatively large visors may beformed for all the automotive vehicles having larger windshields such asluxury cars, sport utility vehicles and the like. At the same time, afamily of relatively small visors might be formed to accommodateautomotive vehicles having smaller windshields such as economy cars,compacts and the like.

[0043] It should be understood that the invention is not limited to theexact embodiment or construction, which has been illustrated anddescribed but that various changes may be made without departing fromthe spirit and the scope of the invention.

What is claimed is:
 1. A method of forming a visor family for automotivevehicles, comprising: providing a first side portion of a first visorwherein at least part of the first side portion is a molded polymer;providing a first side portion of a second visor substantially identicalto the first side portion of the first visor; providing a second sideportion of the first visor, the second side portion of the first visorsupporting a first peripheral component; providing a second side portionof the second visor, the second side portion of the second visorsupporting a second peripheral component different from the firstperipheral component; attaching the second side portion of the firstvisor to the first side portion of the first visor; and attaching thesecond side portion of the second visor to the first side portion of thesecond visor.
 2. A method of forming a visor family as in claim 1wherein the second side portion of the first visor includes a perimeterportion substantially identical to a perimeter portion of the secondside portion of the second visor.
 3. A method of forming a visor familyas in claim 2 wherein the first peripheral component is at least part ofan insert that is attached to the second side portion of the firstvisor.
 4. A method of forming a visor family as in claim 3 wherein thefirst peripheral component includes a vanity.
 5. A method of forming avisor family as in claim 4 wherein the second peripheral component is asecondary visor wall.
 6. A method of forming a visor family as in claim4 wherein the second peripheral is a visor extension.
 7. A method offorming a visor family as in claim 1 wherein the first side portion isat least partially attached to the second side portion via a snapfit. 8.A method of forming a visor family as in claim 1 wherein the injectionmolded polymer includes polypropylene.
 9. A method of forming a visorfamily as in claim 1 wherein the perimeter portion of the first sideportion includes a gripping region, the gripping region including arelatively soft polymer different from the injection molded polymer forproviding a soft feel.
 10. A method of forming a visor family forautomotive vehicles, comprising: providing a first side poriton of afirst visor wherein a first perimeter portion is formed of an injectionmolded polymer and a first insert is attached to and substantiallysurrounded by the first perimeter portion; providing a first sideportion of a second visor wherein a second perimeter portion is formedof an injection molded polymer and a second insert is attached to andsubstantially surrounded by the first perimeter portion and wherein thefirst side portion of the second visor is substantially identical to thefirst side portion of the first visor; providing a second side portionof the first visor, the second side portion of the first visoraccomodating a first peripheral component; providing a second sideportion of the second visor, the second side portion of the second visoraccomodating a second peripheral component different from the firstperipheral component; attaching the second side portion of the firstvisor to the first side portion of the first visor; and attaching thesecond side portion of the second visor to the first side portion of thesecond visor.
 11. A method of forming a visor family as in claim 10wherein the second side portion of the first visor includes a perimeterportion substantially identical to a perimeter portion of the secondside portion of the second visor.
 12. A method of forming a visor familyas in claim 11 wherein the first peripheral component is at least partof an insert that is attached to the second side portion of the firstvisor.
 13. A method of forming a visor family as in claim 12 wherein thefirst peripheral includes a vanity.
 14. A method of forming a visorfamily as in claim 13 wherein the second peripheral is a secondary visorwall.
 15. A method of forming a visor family as in claim 14 wherein thesecondary visor wall includes a hollow interior for selectively housingan extension.
 16. A method of forming a visor family as in claim 13wherein the second peripheral is a visor extension.
 17. A method offorming a visor family as in claim 10 wherein the first side portion isat least partially attached to the second side portion via a snap-fit.18. A method of forming a visor family as in claim 10 wherein theinjection molded polymer includes polypropylene.
 19. A method of forminga visor family as in claim 10 wherein the perimeter portion of the firstside portion includes a gripping region, the gripping region including arelatively soft polymer different from the injection molded polymer forproviding a soft feel.